LED Package Structure for Directional Emission and Color Uniformity
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Solution Overview
Problem
Conventional LED packages face challenges in achieving high light emission efficiency and uniformity, particularly in directing light emissions in desired directions with suitable color uniformity, often requiring encapsulation materials and lenses that increase light loss and non-uniformity.
Innovation Solution
LED packages are designed with lumiphoric material layers forming the exterior light-exiting face, accompanied by light-altering materials on the sidewalls of LED chips, eliminating the need for traditional encapsulation layers and lenses, thereby enhancing directional emission intensity and color uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional encapsulation materials and lenses are used to cover lumiphoric material layers, then mechanical protection and structural integrity are improved, but light loss increases and color uniformity deteriorates
Solution Approach 1:
The patent removes traditional encapsulation materials and lenses from the LED package structure. The lumiphoric material layers themselves form the exterior light-exiting surfaces, eliminating the intermediate encapsulation layers that caused light loss and color non-uniformity while maintaining adequate mechanical protection through the submount structure
Solution Approach 2:
The lumiphoric material layers serve multiple functions simultaneously: they convert light wavelengths, form the exterior light-exiting surfaces, and provide structural definition of the package. This multi-functionality eliminates the need for separate encapsulation materials and lenses
2Stability of the object's composition
If traditional encapsulation materials and lenses are used to cover lumiphoric material layers, then structural integrity is improved, but color uniformity deteriorates
Solution Approach 1:
By removing traditional encapsulation materials and lenses, the patent eliminates the additional interfaces that cause color non-uniformity. The lumiphoric material layers directly form the exterior surfaces, ensuring uniform light emission without the distorting effects of encapsulation materials
Solution Approach 2:
The patent applies lumiphoric materials with specific properties (thickness, composition, particle size distribution) directly at the light-exiting surfaces to optimize color uniformity. The light-altering materials on sidewalls provide localized light redirection to enhance overall color consistency across the emission surface
3Device complexity
If multiple interfaces are present for light to pass through, then structural completeness is improved, but directional emission intensity deteriorates
Solution Approach 1:
The patent removes intermediate encapsulation interfaces, reducing the number of interfaces light must pass through. This minimizes light scattering and absorption at each interface, thereby enhancing directional emission intensity while maintaining structural completeness through the submount and chip mounting structure
Solution Approach 2:
The patent addresses light directionality by working in the angular dimension rather than adding more physical layers. Light-altering materials on sidewalls redirect laterally emitted light toward the forward direction, enhancing directional emission intensity without adding interfaces that would reduce intensity
4Manufacturing precision
If lumiphoric material layers form the exterior light-exiting face, then color uniformity is improved, but the number of components increases
Solution Approach 1:
The lumiphoric material layers perform multiple functions: wavelength conversion, forming exterior light-exiting surfaces, and defining package structure. This multi-functionality improves color uniformity while actually reducing the number of separate components compared to traditional designs with separate encapsulation materials
Solution Approach 2:
The patent merges the functions of lumiphoric material layers and traditional encapsulation materials into a single integrated structure. The lumiphoric materials directly form the exterior surfaces, combining what were previously separate components into one unified element that simplifies the overall device structure
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides improved directional light emission and color uniformity by reducing the number of interfaces light must pass through, resulting in increased light intensity and uniformity, while maintaining a slim profile and mechanical robustness.
Implementation Method 1
Lumiphoric materials, such as phosphors, may be arranged in light emission paths of LED emitters to convert portions of light to different wavelengths
Implementation Method 2
Light-altering materials are provided that cover sidewalls of LED chips
Implementation Method 3
arrangements of light-altering materials and lumiphoric material layers that provide directional light emissions
Data Source
AI summary
Light-emitting diode (LED) packages and more particularly LED packages with directional emission intensity and color uniformity are disclosed. LED packages include one or more LED chips on a submount with arrangements of light-altering materials and lumiphoric material layers that provide directional light emissions with improved color over angle uniformity. Light-altering materials are provided that cover sidewalls of LED chips while lumiphoric material layers cover LED chips and light-altering materials. Such LED packages may avoid the need to include encapsulation materials and/or lenses that would otherwise cover the lumiphoric material layers. As such, exterior light-exiting faces of LED packages are formed by surfaces of lumiphoric material layers.